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Though it has been a few years since I've had one of those apart similar thing happened to me probably 6-7 years ago.
IIRC - and that is a stretch, something is out of alignment slightly (I know, Capt Obvious) that is preventing the slotted cup thingy that engages the spool to fully engage. I don't recall if it is the washers stack on the pinion shaft or specifically if it is (more likely) that the right side plate is not tightened down properly to the spool assembly or that the guts withing the right side plate are not tightened down properly.
Wish I remembered more on it but I think I've had that before but its been a while.
Did you change the drag washers and go with a different brand? Different drag washers with different thickness will change the height of the pinion shaft stack and sometimes needs to be accommodated for.
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